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Generator Fix

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Generator Fix (Oil leaking from generator.)
by Paul Rako
It's scary putting channel locks on a gear but that's the only
way I have been able to do it all these years. Nut is
conventional right hand thread.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only strip the
threads as you turn the nut the wrong way using a half inch
drive impact wrench on 200 PSI air line.
A cheap Taiwan puller is all you need to get the gear off.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only destroy the
delicate tin cover behind the gear when you try to pry the
gear off with a tire iron.

If you want professional results act like a professional.
Have a tray or a pie tin or a mayonnaise jar but at least put
all the parts in one place so you have some chance of
reassembling the generator.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only forget about
the generator and end up taking apart the washing machine
as you look for a pie tin. It will suddenly be 8:00 AM and
you will neither have clean clothes nor a functioning
motorcycle in order to get to work.
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Generator Fix
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This particular generator has a Frank's voltage regulator
mounted on it. A 3/8 inch wrench or nut driver will
remove the field and armature wires. Jot down the colors if
you aren't sure of how they go. There is an "A" and an "F"
stamped in the generator next to the terminals to identify
them.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only strip the
threads as you turn the nut the wrong way using a half inch
drive impact wrench on 200 PSI air line.
I'm showing off using a socket for the cover-- all you really
need is a 7/16 wrench. I did need the socket to get the
regulator off. Please drop a few bucks and buy a set of
phillips screwdrivers and use the right sized one for the
bolt.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only strip the
threads as you turn the nut the wrong way using a half inch
drive impact wrench on 200 PSI air line.

Gently tap end bell off by lightly tapping under the cutouts
with a small rubber mallet. Alternate tapping on both sides
to insure nothing gets bent.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only peen the end-
bell into a ball of useless metal as you use a 2 pound sledge
or, worse yet, you will try to pry the end bell off with that
tire iron you always have so handy.
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Generator Fix
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To get the armature out of the frame you can gently tap on
the armature with a small rubber mallet..
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only peen the
armature into a ball of useless metal as you use a 2 pound
sledge or, worse yet, you will try to pry the end bell off
with that tire iron you always have so handy.
We finally get to see the problem: When the old '62 sat for
a month the motor sumped. This means the oil in the oil
tank leaked down into the motor. When I started it all the
oil was forced into the gearcase. A bunch of oil blew out
the gearcase breather tube but the pressure got high enough
to push this oil seal out of the generator. Oil leaked out the
generator every time I ran the bike since.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. Polishing armature will
have no benefit in generator performance. It is shiny
enough as it is.

Gently tap armature out off the end bell with a small rubber
mallet. I really mean rubber-- if you use a regular hammer
you will mash the threads on the and and life will be
difficult. If you must be a wino at least thread the nut back
on the armature and pound on the nut.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only peen the
armature into a ball of useless metal as you use a 2 pound
sledge or, worse yet, you will try to pry the armature off
with that tire iron you always have so handy.
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Generator Fix
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The seal was still in good condition. It just popped back in
with finger pressure. You could use a tiny tiny tiny bit of
Loctite or Permatex on the outside of the seal but be
extremely careful. The tiniest bit of sealant can get into a
roller bearing and start jamming a ball, making it skate
instead of roll. The entire bearing will melt soon after. It
gets really ugly then because the generator is gear driven
and it will either seize the motor or break off the gear and
then it could get really exciting. Don't glue your bike
together. Silicone and gasket sealant cause horrible
damage in a roller bearing engine. If seal won't pop in then
use a large socket the size of the seal and our friendly
rubber mallet to tap it in.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only mash the seal
into a ball of useless rubber as you use a 2 pound sledge or,
worse yet, you will glob silicone all over the seal that will
get into the motor and seize all the roller bearings..
Assembly is essentially the reverse of disassembly-- good
luck, see ya.
Ha ha, just kidding. We try to be a little more helpful then
the factory manual. Tap the armature in with a small
rubber mallet. Note that the vise is opened way up and
gently tightened on the protruding rings of the end bell.
You aren't supposed to use sandpaper to shine up the
copper commutator because the grit gets stuck in the soft
copper and then grinds up the brushes prematurely. You
aren't supposed to break the speed limit or wear illegal
helmets either and I do that too. The armature lathe I
bought on e-bay isn't here yet.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will ruin the bearing
surface by bashing with a two pound sledge. You will
tighten the vise on one side of the armature and hammer on
the other side. It will get ruined. It always does. Get wise.

It's usually easier to put the brush plate on after the frame is
installed. This plate was too snug to pop out so the handle
of the mallet was used to gently tap it free. You can leave
the wire attached but don't get too rude with it. I also was
using paper towels to dry off any oil on the parts.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. An ox acetylene cutting
torch will not help in removing the plate and will have

Generator Fix
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Look carefully at the little paper spacer under the square
head of the field terminal. If the terminal was torqued too
hard this thin paper gets cut and the field gets shorted to the
armature and the generator has no output. There are some
plastic spacers around but I haven't found them yet.
Anything including the plastic from a milk bottle is better
then nothing. If you tighten the terminal up carefully you
can insure the corner of the square head is not cutting
through the spacer. This is a design flaw in the 65A
generator.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will only end up with
all the parts in a pile and no way to get it back together.
That's what always happens remember?
Note the little pin in the frame and the little slot in the
brush plate. It has to go together one way only.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will mash the brush
plate in backwards and the generator will never work again.

Note the little pin in the frame and the hole in the gear side
end bell. It can only go together one way.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. No matter how hard you
pound the sledge hammer, the pin will not make a new
hole.
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Generator Fix
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The frame didn't want to slip on so I pulled it from the vise
and after cleaning the pin and hole, I gently tapped the end
bell on with a small rubber mallet.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. It will never occur to you
that the 2 pound sledge is not appropriate for generator
work, but it is. Honest.
The brush plate should have enough wire to slip on after
the frame and end-bell are assembled. Otherwise you may
have to remove the wire or assemble the frame to the end-
bell with the brush plate in place. See next step for getting
the brushes over the armature. Remember the little slot in
the plate and the pin in the frame have to line up.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will break wire or
mange to get plate installed backwards.

I dried off the brushes and slipped them back in the
holders. You can use two hands because you aren't taking
a picture at the same time.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. This is hard to do for
straight people and winos. Doing while shaking
uncontrollably and hallucinating is virtually impossible.
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Generator Fix
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One wire is rubbing against the commutator and the other
will get pinched by the end-bell. Bend them back out of
the way or loosen and re-tighten the terminal to keep them
out of harm's way.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. Sparks and fire will ensue
when you pinch wires. It will be "really cool man" but
your generator will still be broken.
Note that same little pin in the frame picks up a slot in the
end bell. It can only go together one way.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will smash pin and
generator will never work right again.

Since the voltage regulator uses the generator bolts I loose
assembled the brush cover. I used to run without the cover
to let cool air into the generator. It worked great in the
rain, everywhere for 5 years. Until I blew a front fork seal
and the fork oil splashed on the commutator. It glazed it
over and ruined the voltage regulator. I went back to
running the cover.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. An impact wrench will only
strip out the tiny screw.
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Generator Fix
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Because of the regulator I needed a deep well socket.
Otherwise a 7/16 wrench will work. Always replace the
lockwashers-- even if you tightened it and then had to take
it back off for some reason. A brand new lockwasher every
single time forever and always. Then you will not have to
glue your bike together with Loctite. I replace the nylon
prevailing torque nuts the factory uses with regular nits and
lockwashers. Regular nuts free run the way god intended
and all you have to do is buy a bag of lockwashers for less
then a penny a piece and you are in business.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. Half inch impact drive will
strip nuts or snap off studs or make studs spin in the end
bell housing..
Now you can tighten the brush cover. This on is eye-balled
so it points down when the generator is installed. This area
was were the oil was coming out..
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will strip out this little
screw for sure and the tab will hit the frame when you go to
install it. You will use torch to bend frame out of the way
rather then reposition the tab. It's all downhill from there.

For this setup that uses a Franks electric regulator you can
hook the field and armature wires up now. Check your
notes and you do have the original instructions on file don't
you? Don't trust the color on these wires. Different
regulators have different colors. Note the little internal
tooth star lockwashers that insure good electrical contact.
The hardware store is your friend. Spend time with your
friends.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will reverse wires and
melt generator.
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Generator Fix
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Even non meth-amphetamine addicts can strip these 10-32
brass nuts. I turn the wrench like this or use a nut-driver.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You know what happens
here, right? Every time. You have no nerve endings left in
your hands. You cannot do work this delicate. Give up.
Make sure everything is spotlessly clean and especially this
bearing cover. Dirt and grime in a precision ball bearing is
not good.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will have lost this piece
by now and yes, it really is needed.

The gear will only start on the shaft as it is a light press fit.
Some gears do just slide on. Make sure it has started on ok
and put the big washer and nut on and you can pull it on as
tighten the nut. Factory uses nylon prevailing torque nut. I
substitute regular 1/4-28 nut and a pair of the trick Disk-
Lock lockwashers. A real touch here as you need to feel
the subtle difference of the gear pulling on and, once it all
the way on, the increase in torque as the nut tightens.
These 1/4-28 threads strip easy. Be careful. Insert goofy
zen parable here about ending up where we started. (Except
for the oil leak.)
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. The more common 1/4-20
course thread nuts will ruin the armature (and the end bell
studs for that matter).
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Generator Fix
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See why professionals use the trays? The only things left
over are the 3 lockwashers that were replaced with new
ones. One for the armature nut, two others for the end bell
studs.
Meth-amphetamine addicts: STOP NOW. Take generator
to qualified service personnel. You will have parts left
over and scattered in the gravel driveway. There will be
parts from a Lucas MGA magneto in the generator. Every
threaded fastener will be stripped and the generator will no
longer be repairable by anyone, even a qualified service
professional.
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